MSK-E

AC Servo ModulesMSK 6

MSK 12

Power Supply Module

MTB 25

MSKAll data in this manual is informative.

Specifications are subject to change without notice.

2

MSKContents

1.2.3.

Page

Safety regulations................................................................................................................4Technical specifications.......................................................................................................5Installation...........................................................................................................................73.1.Conductor cross sections.............................................................................................73.2.Inputs and outputs........................................................................................................73.3.Motherboard connections (MB-MSK)............................................................................93.4.Connections on the front of the servo module............................................................103.5.Motherboard connections (MB-MTB)..........................................................................103.6.Selection of transformers............................................................................................113.7.Connecting the servo motor........................................................................................114.Set-up Procedure..............................................................................................................115.Functions and Options.......................................................................................................125.1.Function of the controls and indicators on the MSK 6/12 modules..............................125.1.1.Test jacks................................................................................................................125.1.2.LED indicators.........................................................................................................125.2.Controls......................................................................................................................135.3.Indicators on the power supply module MTB-25.........................................................145.4.Personality module.....................................................................................................145.4.1.RMS current limitation.............................................................................................145.4.2.Peak current limitation.............................................................................................155.4.3.RMS and peak current limitation with fixed resistors...............................................155.4.4.Components on the personality module..................................................................165.4.5.Location of the personality module..........................................................................175.4.6.Input circuitry - velocity controller incl. personality module......................................185.5.Options.......................................................................................................................195.5.1.Encoder simulation \"ES1\".......................................................................................195.5.2.Option \"24 V external\".............................................................................................195.5.3.Optional power supply \"24 V external\" with integrated power dump resistor...........206.Trouble shooting................................................................................................................206.1.Fuses MSK 6/MSK 12................................................................................................206.2.Fuses - MTB 25..........................................................................................................216.2.1.Fuses - optional power supply.................................................................................216.3.Trouble shooting table................................................................................................227.Connection diagrams.........................................................................................................277.1.Connection diagram - MTB-25....................................................................................277.2.Connection diagram - MTB-25/MSK 6/MSK 12 with option \"24V external\"..................287.3.Connection diagram MSK 6/MSK 12 with motors M254-M506 and F504-F804..........297.4.Front panel - MSK 6 / MSK 12 and MTB 25................................................................307.5.Dimensions.................................................................................................................318.Ordering details.................................................................................................................328.1.Order code for MSK, MTB and motherboards............................................................328.2.Order code for power dump resistors.........................................................................338.3.Order code for rack system........................................................................................339.Appendix............................................................................................................................349.1.Transformer dimensions and order code....................................................................349.2.Motor cables...............................................................................................................349.3.Resolver cable............................................................................................................34

3

MSK1. Safety regulations

Installation and start-up should be performed by skilled and qualified staff, observing valid

VDE regulations.

VDE 0100 (Erection of Electrical Power Installations with Rated Voltages Lower Than 1000V).

VDE 0130 (Electrical Equipment of Manufacturing and Processing Machines).VDE 0160 (Assembly of Electronic Equipment in Power Installations).

The AC input power to the module has to be supplied by an isolated transformer (see VDE0550).

The negative Uz bus has to be grounded (connection to the 19\" rack is provided by themotherboards).

For the motor an earth connection is required (PE connection on the motherboards).The negative Uz bus (PE) has to be connected to the ground point in the cabinet.

The minimum gauge of the motor and supply cables has to be rated according to VDE0100. Please ensure an ample rating when using longer cables.

Motor and resolver cables must be shielded and connected to the motherboard on oneside.

The resolver lead wires should be run as twisted pairs.

The cable for the velocity command signal has to be shielded and connected to the moduleon one side.

The use of a potential free standby contact in the safety circuit of the machine will increasethe operating safety of the system.

Before clearing a fault by means of the reset command eliminate the cause and make surethat carrying out the command is not dangerous.

When working on, or in the vicinity of the machine the power must be disconnected fromthe drive in accordance with VDE 105.

Note:Removing the \"Enable\" signal is not sufficient to disconnect the power!

The modules must be mounted in the vertical position.Filtered air (Vu ≤ 45oC) is required for cooling.

The modules may only be inserted and removed after disconnecting the power (themodules are without any potential after 5 seconds).

When using the option \"24 Vex.\" it is necessary to observe the specified switch-onsequence: connect the 24 Vex.. auxiliary voltage first and then apply AC power.Switch-off is in the reverse sequence.

4

MSK2. Technical specifications

Rated valuesBus voltage

Logic voltage (internal)Rated output voltageRated output currentPeak output currentProtection (internal)DC bus

Auxiliary voltage

Tripping threshold for over-voltage

Tripping threshold for over-temperatureChopper frequency of the output stageBandwidth of the current controllerAuxiliary DC outputsResolver voltage

MSK12: 16 A mb (5 × 20 mm) / MSK6: 8 A mb630 mA mb

1.25 A mb with 24 V option> 170 V> 85oC9.8 kHz> 1.5 kHz

± 15 V, 10 mA7.07 Vrms, 10 kHz

120 V DC (55 V DC...140 V DC)+15 V, 600 mA; -15 V, 400 mA74 Vrms (3 × 34 Vrms...83 Vrms)MSK 6:3 × 4.2 ArmsMSK 12:3 × 8.5 ArmsMSK 6:3 × 8.8 ArmsMSK 12:3 × 17.6 Arms

Vel. command input 1 via ramp generator± 10 V, Ri= 20 KΩ

50-500 ms, 10 V, 0...100%

Vel. command input 2± 10 V, Ri = 20 KΩCurrent limitation input (2 × In)0...10 V, Ri = 1 KΩEnablePLC compatible, 11-33 V DC; active HighLimit switch enable (forward)PLC compatible, 11-33 V DC; active HighLimit switch enable (reverse)PLC compatible, 11-33 V DC; active HighResetPLC compatible, 11-33 V DC; active High; 1msOutputsController busyI2 × t limitReady relayBrake relayOptions:

Encoder simulation (opto-isolated)External power supplyOutput levelOutput signalsResolution

+ 5 V DC, 50 mA5 V (RS 422)

A, A, B, B, and gated I, Iadjustable 128, 256, 512, 1024 counts per revolution

open collector, active Low 35 V DC, 20 mAopen collector, active Low 35 V DC, 20 mArelay energised, 24 V DC, 500 mA NCrelay energised, 24 V DC, 500 mA NC

5

MSKExternal 24 V DC power supply:Auxiliary voltageMonitor devicesCurrent monitorVelocity monitorPower supply MTB 25

Rated connection voltageRated output voltageRated input currentRated output currentMains fuses (internal)

Peak power of dump circuitwith external resistor

Continuous power of power dump circuitSwitching threshold of power dump circuitProtection of the dump circuitOption:

Internal dump resistor and auxiliary power supply 24 V DCPeak power of the internal dump resistorContinuous power of the internal

dump resistor without/with forced coolingRated value of the auxiliary voltage

Rated current (1-phase/3-phase supply)Rated input voltage

Rated input current (1-phase/3-phase)Protection of the auxiliary voltage

650 W

30 W / 60 W

24 V DC (20...28 V DC)2 A DC/4 A DC

1 × 19 Vrms / 3 × 19 Vrms (15.5...21 Vrms)1 × 3 Arms / 3 × 3.3 Arms3 × 4 A mb (5 × 20 mm)3 × 85 Vrms (40 Vrms...95 Vrms)120 V DC (55 V DC...140 V DC)3 × 20 Arms25 A DC

3 × 16 A sb (5 × 20 mm)3.2 kW8 Ω, 500 W500 WUz + 15 V

8 A sb (5 x 20 mm)0... ± 2 × ln = 0... ±10 V0... ± 8000 rpm = 0... ±8 V24 V DC, 500 mA (18...30 V DC)

6

MSK3. Installation

Environment

The ambient temperature must be between 0 and 45 oC. If this is not guaranteed, the

output current has to be linearly reduced from In at 45 oC down to 0 A at 85 oC. If the RMScurrent is higher than 6.3 Arms forced cooling is generally required. Forced cooling is alsonecessary for multilevel arrangement of 2 or more racks, even with low RMS currents. Inthis case a fan has to be provided under every one or two modules. In multilevelarrangement the modules subjected to the greatest loads must be on the bottom.

Similarly, the power supply module MTB 25 also has to have forced cooling from 20 A DCand above. If the load of the built-in dump resistor of the 24 V power supply option is higherthan 30 W, a fan must be installed under the power supply module or under a power supplymodule and a servo module. An air velocity of 5 - 10 m/sec is generally sufficient.If the cabinet has an external cooling system, the supply air must be filtered.

The maximum relative humidity is 90% non-condensing. The maximum altitude is 1000 mabove sea level.

3.1. Conductor cross sections

Motor cables:Resolver cables:

Velocity command signals:Control signals:Power cable:24 V external:

4 × 1.5 mm2 minimum

4 × 2 × 0.14 mm2, twisted pairs0.14 mm2, twisted pairs0.28 mm2

4 × 2.5 mm2 minimum2 × 1 mm2 minimum

For the initial set-up suitable cable sets in graduated lengths are available from Messrs.Bautz (see Appendix).

For the suppression of EMI the motor cable as well as the resolver cable must be shielded.The shielded cable should be connected on one side of the motherboard of the module.If the motor lead is not shielded, it should not run parallel with the resolver and velocitycommand signal.

3.2. Inputs and outputs

The voltage for the limit switches can be supplied both from an external 24 V source orinternally (+15 V int. - pin 6). The reference ground is pin 3 or 9 on the front panel Sub-Dconnector (GND).

Note:This reference ground is not isolated from PE / -Uz !

When the corresponding limit switch is activated the motor is actively braked to standstill,the brake relay is then opened and after approx. 20 ms the servo module is disabled.

Emergency switch-off caused by simultaneous opening of both limit switches ensures fastbraking followed by opening of the brake relay. On the other hand, by removing the enablesignal the drive is immediately disabled and the brake relay opens immediately.

The rating for both relays is 24 V DC, 0.5 A. Therefore a power relay is required for a motorbrake. This relay must be protected by varistors etc.

The outputs \"I2 × t\" and \"Controller busy\" are open collector outputs for max. 33 V DC,20 mA. The reference ground is pin 4.

7

MSKWhen the current of the servo module rises above its rated RMS value, the output \"I2 × t\"becomes active (low resistance).

The output \"Controller busy\" indicates the standby status of the servo module, and that\"enable\" and the \"limit\" switches are closed.

The \"Reset\" input clears a fault message stored in the memory. This input should beactivated for only about 1 ms; the cause of the fault should be removed first.

The \"Imax extern\" input is provided for external current limitation using a DC voltage 0 - 10V DC. The internal resistance should not be greater than 100 Ω. Also, a potentiometer of10 KΩ may be used.

The reference ground is pin 3 or 9 of the front connector.

Front connector X515-pin SUB D socket

Solder side of the mating connector

8

MSK3.3. Motherboard connections (MB-MSK)

OPTIONencoder-simulation

OPTION24V ext.

ConnectorPinX11X2

1X3

1234567X4

1234X6

123X7

123456710

X812X9

1234567X1012X11

12

Function

Soldering pin +VccSoldering pin -VccIndexAB

+5 V externalncIndexAB

GND external

GND + motor shieldPhase T (motor)Phase S (motor)Phase R (motor)

+15 V, 10 mA aux. voltageGND of auxiliary voltage-15 V, 10 mA aux. voltageNsoll = Veloc.command 2-internally for PTS

Nsoll = Veloc.command 2+internally for PTS

Internal enable for PTSGND

Encoder A for PTSEncoder B for PTSPTS errorncncnc

Brake relay 24 V, 500 mABrake relay 24 V, 500 mAThermo switch for motorThermo switch for motorExcitation voltage R2Excitation voltage R1Resolver Sine S4Resolver Sine S2Resolver Cosine S1Resolver Cosine S3Shield

Opt. +24 V externalOpt. GND for 24V ext.Standby relay 24 V, 500 mAStandby relay 24 V, 500 mA

9

Cross sectionmin. 2.5 mm2min.2.5 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm2min. 1.5 mm2min. 1.5 mm2min. 1.5 mm2min. 1.5 mm20.14 mm20.14 mm20.14 mm2ribbon cableribbon cableribbon cableribbon cableribbon cableribbon cableribbon cable

min. 0.5 mm2min. 0.5 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm21 mm21 mm20.5 mm20.5 mm2

MSK3.4. Connections on the front of the servo module

ConnectorPinFunctionX5

1Reset

2Controller busy, open collector3GND4GND

5Enable (forward)

6+15 V for limit switch ?7Veloc. command 2+8Veloc. command 1-9GND

10I11max external

I2 × t limit, open collector12Enable

13Enable (reverse)14Veloc. command 2-15

Veloc. command 1+

3.5. Motherboard connections (MB-MTB)

ConnectorPinFunctionX11Soldering pin +VccX21Soldering pin -VccX4

1PE isolation transformer2L1: 85 V3L2: 85 Vrms4L3: 85 Vrmsrms

X5

1RB+ ext. dump resistor2RB- ext. dump resistorOPTIONX6

119 Vrms for 24 V external24V ext.219 Vrms for 24 V external319 Vrms for 24 V externalOPTIONX7

124 V DC output 4 A DC24V ext.

2

24 V DC GND

10

Cross section0.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm20.14 mm2

Cross sectionmin. 2.5 mm2min. 2.5 mm2min. 2.5 mm2min. 2.5 mm2min. 2.5 mm2min. 2.5 mm2min. 1.5 mm2min. 1.5 mm2min. 1 mm2min. 1 mm2min. 1 mm2min. 1 mm2min. 1 mm2

MSK3.6. Selection of transformers

The following transformers to VDE 0550 are available for servo modules of seriesMSK 6 / 12:

TypeTO65.1TO66.1TO118.1TO119VA0.5 kVA1 kVA1 kVA2.3 kVARating Primary1 × 230 Vrms1 × 230 Vrms3 × 400 Vrms3 × 400 VrmsSecondary1 × 85 Vrms / 5.5 A1 × 85 Vrms / 11 A3 × 85 Vrms / 6.3 A3 × 85 Vrms / 15.1 AAuxiliary1 × 19 V / 1.5 A1 × 19 V / 2.5 A3 × 19 V / 2.5 A3 × 19 V / 2.5 ABefore connecting the transformer to the power supply module measure the secondaryvoltage with a voltmeter.

For transformers over 3 kVA a soft-start has to be provided.

When using the external 24 V supply it is necessary to provide a power relay in thesecondary 85 V; this relay is energised by the auxiliary 24 V voltage.

In this way the correct switching-on and switching-off sequence is assured. The relay alsoensures \"safe removal of power\" in the event of an emergency switch-off.

3.7. Connecting the servo motor

The MSK modules may be used in conjunction with all motors of series M254...M506 andF50...F80. A personality module is used to match the controller to the motor; the

personality module is accessible by removing the front panel. Please note the necessaryRMS current matching for the thermal protection of the motors. (see page 14 and 15).On request the modules are delivered with already adjusted personality modules.

4. Set-up Procedure

Please read the safety instructions given in chapter 1!

Check the wiring according to the diagrams in chapter 7.

Check the name plates of the controller, motor and transformer for the right voltage,current and correct wiring.

Make sure that the trimming potentiometers are set in their normal position (see page 13).Check that the earth connections are correct (common ground point), especially the shieldof the transformer. Make sure no damage is done in case the motor accelerates towardsfull speed.

Set the Imax potentiometer close to the fully CCW position to limit the maximum torque ofthe motor.

When switching the drive on for the first time, disable the drive and then apply AC power (ifusing the 24 V option, make sure that the switching sequence is in the specified order).When AC power is applied and the controller enabled, move the axis in both directions atslow speed. Check that the polarity of the velocity command signal and the direction ofrotation of the motor are correct.

Adjust all potentiometers (Nist, Nsoll, offset, Gain, Imax and Irms).

If further axes are to be put into operation, make sure that the power has been safelyremoved from the system before the modules are inserted.

11

MSK5. Functions and Options

5.1. Function of the controls and indicators on the MSK 6/12 modules

5.1.1. Test jacks

There are 2 test jacks (2 mm) for the actual value of velocity and current.Velocity monitor \"VEL\"

Current monitor \"CUR\"

1 V1 V

= 1000 rpm= 20 % of the rated currentThe reference ground is the \"GND\" jack.

To avoid earth circuit always use potential-free oscilloscopes or isolation transformers.Likewise, the GND jack should be free of any other connections.

5.1.2. LED indicators

\"LIM\" LED

Indicates that one or both limit switches were hit. For normal operation both limit switches

must be closed.\"I2 × t\" LED

This LED is turned on if the permissible peak current was drawn for too long.LED \"Über-Temp\" (over-temperature)

This LED is turned on if the temperature in the module exceeds 85 oC or when the thermoswitch responds.

If a thermo switch is not provided, pins 1 and 2 of X9 on the motherboard of the servomodule have to be bridged.LED \"Überstrom\" (over-current)

All MSK servo modules are protected against short-circuit phase to phase and phase toground. If a short-circuit occurs the servo module is switched off and the LED \"Überstrom\"lights.

LED \"+ 15 V def\" (auxiliary voltage error)

This LED lights if one or both of the auxiliary voltages drops below 14 V.LED \"Überspg\" (over-voltage)

This LED lights if the DC bus voltage exceeds 170 V.LED \"Unterspg\" (under-voltage)

This LED lights if the DC bus voltage drops below 55 V or if the AC power is off when usingthe option \"24 V external\".

The fault messages \"Übertemphe same time the standby relay and the brake relay are de-energised and the output\"Controller busy\" relay contacts open.

The fault messages may be cleared with a \"Reset\" signal on pin 1 of the front connectorX5, or by switching the AC power off and then on again. Please remedy the fault conditionbefore you reset!

12

MSK5.2. Controls

Potentiometer \"dn/dt\"

This potentiometer sets the slope of the velocity command integrator (50 ms - 500 ms) forvelocity command input 1. The basic setting is fully CCW.Potentiometer \"Nist\"

This potentiometer reduces the tacho gain, i.e. the motor speed can be increased while thevelocity command signal remains unchanged. The basic setting is fully CCW.Potentiometer \"Nsoll\"

This potentiometer reduces the velocity command gain. The potentiometer is active on bothinput channels. The basic setting is fully CW.Potentiometer \"offset\"

This potentiometer is used to adjust the speed drift of the drive with a velocity commandsignal of 0 V.

(Note: Unused velocity command inputs have to be short-circuited.)Potentiometer \"Gain\"

This potentiometer increases the gain of the velocity controller. By turning it CW both theproportional and integral component increase uniformly. For special applications the

individual parameters on the personality module may be changed. The basic setting is fullyCCW.

Potentiometer \"Imax\"

By turning this potentiometer CCW it is possible to reduce the peak current linearly down tozero. The basic setting is fully CW.Potentiometer \"Irms\"

By turning this potentiometer CCW the RMS current of the servo module may be reduceddown to 25% of the rated current. The control range has a quadratic character, i.e. thecentral position corresponds to about 70 % of the rated current of the servo module. Forexact matching of controller and motor please consult table 2 on page 15.The basic setting is fully CW.DIL switches for setting the pole pairs:

No. of motor pole pairs23 (Standard)48Table 1

S 2aoffoffononS 2bonoffoffon13

MSK5.3. Indicators on the power supply module MTB-25

The power supply modules of series MTB generate the bus voltage for the AC servomodules of series MSK.

An external single-phase or three-phase isolation transformer delivers the required inputpower.

With single-phase operation the power output is reduced. The power supply module MTB25-AB has an internal power dump resistor and an auxiliary voltage of 24V.

LED \"Uz\"

This LED will be on if voltage is present on the DC bus. Do not remove the MTB 25 fromthe rack when this LED is on!

LED \"Ballast\" (power dump)

Lights during braking of the drive when the energy generated by the motor is being

converted into heat in the power dump resistor. When the supply voltage is switched off thedump circuit quickly discharges the capacitors. Please use power dump resistors asspecified in the appendix (the option \"24 V external\" has a built-in power dump resistor).

5.4. Personality module

All parameter setting options are contained on a small pc board. This allows optimum

adaptation of the servo module to a certain motor and to the motion control application inquestion. The pc board can be configured into a personality module if the specificparameters are designed with fixed resistors and jumpers.

The following components are placed on solder-type sockets and may be changed:

DesignationR98C9R83R87FunctionProportional gainTime constantImax limitIrms limitValue (Standard)150 KΩ100 nFopenopen5.4.1. RMS current limitation

The resistor R87 limits the RMS current of the servo module:

Fig. 1

Example: Servo motor M406D, In = 5.6 Arms in conj. with MSK 12, Irms = 8.5 A

InIrms

=

5.6A

=0.68.5A

i.e.R87=390Ω

14

MSK5.4.2. Peak current limitation

The resistor R83 limits the peak current of the servo module:

Fig. 2

Example: Motor M406D, Imax= 2 × In = 11.2 A in conj. with MSK 12, Imax= 17.7 A

Imotor112.A

==0.63Iampl.17.7A

i.e.R83=15.kΩ

5.4.3. RMS and peak current limitation with fixed resistors

Recommendedservo moduleMSK 6MSK 6MSK 12MSK 12MSK 12MSK 12MSK 12MSK 12MSK 12MSK 12MSK 6MSK 6MSK 12MotorM 254BM 256BM 404BM 404CM 404DM 406CM 406DM 504EM 504FM 506FF 504F 634F 804In rms[A]2.84.38.24.82..65.69.46.59.72.33.27.5Table 2

R87[Ω]390--27068-390-560-270560820Imax rms[A]5.68.616.49.65.619.211.218.813.019.44.66.415.0R83[Ω]1.3k--1k430-1.5k-2k-1k2k3k15

MSK5.4.4. Components on the personality module

Fig. 3

16

MSK5.4.5. Location of the personality module

Fig. 4

17

MSK5.4.6. Input circuitry - velocity controller incl. personality module

Fig. 5

18

MSK5.5. Options

5.5.1. Encoder simulation \"ES1\"

Each module of the MSK series can be provided with this option (subsequent extensionpossible). The outputs are opto-isolated for better noise suppression and require anexternal power supply +5 V/50 mA. The output drivers (LS26C31) supply 5 V to RS 422.The encoder simulation generates two pulse trains shifted by 90o with max. 1024 countsper revolution. The index is gated. The index cannot be shifted electrically.

Fig. 6

Pulse diagram for CW rotation

Setting the resolutionResolution1282565121,024 (Standard)Table 3

Switch 1offoffononSwitch 2offonoffonFig. 7

Position of switches 1 and 2

5.5.2. Option \"24 V external\"

This option uses an external 24 V source to prevent loss of stored error messages in theservo module or of encoder signals in the event of an emergency shutdown or other faultcondition. For this purpose a power relay has to be provided in the AC power supply aheadof the power supply module. Its function is to switch off the DC bus voltage in the case of afault, in compliance with VDE regulations for emergency shutdown. It is also possible touse the 24 V voltage of a PLC as source. In this case the 24V supply is not isolated fromUz and PE.

19

MSK5.5.3. Optional power supply \"24 V external\" with integrated power dump resistor

The standard power supply module can be fitted with the optional board \"24 V externalsupply with integrated power dump resistor\" (subsequent extension also possible). The ACpower has to be connected at X6 on the motherboard of the power supply module. With a3-phase supply it is possible to power 6 MSK modules with a reserve of 1 A for auxiliarycircuits.

The integrated power dump resistor (40 Ω) is rated for 30 W/60 W without/with forcedventilation. For higher loads an external power dump resistor (8 Ω/100 W..500 W) has tobe connected in parallel via connector X5 on the motherboard of the power supply module.

6. Trouble shooting

6.1. Fuses MSK 6/MSK 12

The fuses F1 and F2 can be replaced using suitable pliers. Please use the following fuse

ratings:

F1630 mA/mb630 mA/mbF1 (OPT 24 V external)1.25 A/mb1.25 A/mbF28 A/sb16 A/sbMSK 6MSK 12Fig. 8

Location of fuses on MSK

20

MSK6.2. Fuses - MTB 25

To replace the fuses at the input of the power supply module and the fuses of the powerdump resistor use suitable pliers.

Fuses at the input of the power supply unitPower dump resistor

F1, F2, F3= 16 A/sbF4

= 8 A/sb

Fig. 9

Location of fuses on MTB 25

6.2.1. Fuses - optional power supply

The fuses for the auxiliary voltage supply can be replaced using suitable pliers.Rating of fuses F1, F2, F3 = 4 A/sb

Fig. 10

Components on the 24 Vext option with integrated power dump resistors - location of fuses-

21

MSK6.3. Trouble shooting table

Problems during set-up are mostly due to incorrect wiring or false settings of the modules.The table on page 23 contains a summary of various problem symptoms and their possiblecauses.

Most faults can be remedied by the user, observing the drive and state of the LEDs.

22

MSKTrouble shooting table:

Power supplymoduleSymptomThe motor does not runUzPower dumpServo moduleStatus of LEDsLIMI2 × tOver-temp.Over-curr.±15VOver-volt.{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{Rated speed is not reachedMotor speed oscillatesMotor speed is too lowMotor speed is too highMotor accelerates / deceleratestoo fast or too slowZero speed of motoris not possible{{{{{{{{{{{{{{{Table 4

{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{{Under-volt.Refer to no.{1{2,33{5{6{7{8{9{10{11{12{13{14{15{16{17Explanation LED on { LED off

23

MSKIf something goes wrong:

1.

a) No voltage (3 × 85 Vrms) on the power supply module.Remedy:Check the connection.

b) Defective power supply module and/or blown fuses.

Remedy:Check the fuses and/or replace the power supply module.2.

a) No bus connection between the motherboard of the power supply module and themotherboard of the servo module.Remedy:Connect using suitable cables (2.5 mm2).

b) Blown fuse F1 of the servo module or no auxiliary voltage on the \"24 V external\"option.

Remedy:Check the fuse and/or restore the auxiliary voltage.3.

a) Blown fuse F2 of the servo module or no voltage (3 × 85 V) between the \"24 Vexternal\" option and the power supply module.

Remedy:Check the fuse and/or restore the voltages.4.

a) \"Enable\" input is not connected.Remedy:Make the minimal connections to get the drive running (see page 28).

b) Defective servo module.

Remedy:Change the servo module.5.

a) LED \"LIM\" is on. A limit switch has been hit, or both enable inputs for the limit switchare not connected.

Remedy:Move the axis from the limit switch with an inverted velocity command, or

connect the \"Enable forward\" or \"Enable reverse\" input at the frontconnector X5.6.

a) The servo module is overheated.Remedy:Allow the servo module to cool down, use forced ventilation or reduce the

ambient temperature as required.

b) The thermo switch of the motor was tripped due to an incorrectly sized motor and/orresolver connection, or the torque drawn from the motor was too high for a longertime.Remedy:Check motor and resolver cable.

Check whether the motor has been sized properly, check motor

environment (temperature, flange cooling).

c) The motor has no thermo switch or the thermo switch is not connected.

Remedy:Connect the thermo switch to pin 1 and 2 of connector X9 or bridge the

connection. In the absence of a thermo switch the motor has to be

protected by the RMS current limitation in the servo module (see page 14 and 15).7.

a) External short-circuit between the motor phases.Remedy:Check for a short-circuit in the motor cable and make sure that the

resistance between the phases has the same value.

b) Short circuit phase to ground

Remedy:Check the motor phases/motor cable for a short circuit phase to ground

and/or check the motor connector and replace it if necessary.8.

a) LED \"±15 V\" is on. One of the auxiliary voltages is <14 V.

Remedy:The auxiliary voltage output at connector X6 draws more than 10 mA or the

servo module is defective. Replace the servo module.

24

MSK9. LED \"Überspg.\" (over-voltage) is on.a) AC power is higher than 3 × 95 VrmsRemedy:Check AC power input; use only the recommended transformers.

b) No power dump resistor.Remedy:Connect the power dump resistor as shown in the Appendix - see page 27,

28 and 34. (Not applicable for the option \"24 V external with integrated power dump resistor\").

c) Multi-axis operation: All axes had to stop at the same time (e.g. emergency stop).The resistance of the power dump resistor may be too high.

Remedy:Use resistors of Rmin = 8 Ω or an additional external resistor connected in

parallel to the integrated power dump resistor.

d) Blown power dump fuse.Remedy:Check the fuse F4 8 A/sb and replace if necessary. (See page 21 Location

of fuses on power supply module).10. LED \"Ballast\" is on.

a) Without a power dump resistor the \"Ballast\" LED may flicker. This does not indicatean incorrect function.

b) With a connected power dump resistor the LED flickers when the axis is braked. Theenergy in the power dump resistor is converted into heat. This is a correct function.c) With a connected power dump resistor the LED is permanently illuminated.Remedy:Defective power supply module. Replace the unit.11. The drive does not reach the rated speed.

a) No velocity command signal, or its gain is too low.Remedy:Turn the potentiometer \"Nsoll\" CW or connect the velocity command signal

to X5 on the front panel.

b) The voltage constant of the respective motor is too high, or the bus voltage drops to avalue that is too low, especially with a single-phase line voltage.Remedy:Check the voltage requirements of the motor and the AC power supply.

c) The potentiometer \"Imax\" is not turned fully CW or the external current limitation isactive.

Remedy:Turn the potentiometer \"Imax\" up or increase the current limit.12. The drive does not reach its rated speed and the LED \"I2 × t\" is on.

a) The requested torque is higher than the nominal torque of the motor or thepotentiometer \"Irms\" is not turned fully CW.Remedy:Check the torque of the load and the friction torques of the equipment and

compare against the motor/controller data.

b) Reversed supply leads of the motor and/or resolver.Remedy:Check the connection against the wiring diagram on page 29.

c) The servo module limited the peak current because the RMS torque of the motor wasexceeded at high speeds.

Remedy:Reduce the torque of the load or use a servo module and motor with a

higher output power.13. The motor speed oscillates.

a) The \"Gain\" potentiometer is set too high.Remedy:Turn the potentiometer back CCW until the tacho monitor does not show

any oscillation.

b) Even in the fully CCW position of the \"Gain\" potentiometer the motor still oscillates.Remedy:Reduce the value of R98 to 68 kΩ and increase C9 to 330 nF on the

personality module (see page 16).

25

MSKc) The motor still oscillates after carrying out b).Remedy:Check the mechanical connection of your machine with the motor,

especially the coupling. The coupling should be stiff against torsional forces. Elastic

power transmission elements such as belts and rubber couplings should beavoided where possible.

d) The existing gears or couplings show backlash.

Remedy:Use gears and couplings with minimum backlash.14. The motor speed is too slow.

a) The potentiometer \"Nsoll\" is not turned fully CW.

Remedy:Turn the potentiometer CW until reaching \"Nsoll\".

b) The potentiometer \"Nist\" is turned fully CCW.Remedy:First turn the potentiometer \"Nsoll\" to the fully CW position and then turn the potentiometer \"Nist\" CW until reaching \"Nsoll\".c) The voltage at the velocity command input is too low.

Remedy:The velocity command input voltage should be 8 - 10 V for the maximum

speed in order to increase the signal-to-noise ratio.15. The motor speed is too high.

a) The sum of both velocity command inputs is too high.Remedy:Reduce the voltage on both inputs.

b) The potentiometer \"Nsoll\" is turned fully CW.

Remedy:Turn the potentiometer \"Nsoll\" CCW. If the setting range is too large

towards slower speeds, increase R94 (nom = 20 kΩ) on the personality module to

47 kΩ (see page 16).16. The motor accelerates/decelerates either too fast or too slow.

Remedy:Set the ramp using the \"dn/dt\" potentiometer. Fully CCW position

corresponds to minimum, fully CW position corresponds to maximum acceleration/deceleration of the motor.

Note:The \"dn/dt\" potentiometer acts only on velocity command input 1!17. Zero speed of the motor is not possible.

a) One or both of the velocity command signals has offset.Remedy:Feed both velocity command signals from SPS to servo module

differentially. Velocity command inputs not being used should be short-circuited.

b) The offset potentiometer is not set.

Remedy:Adjust the offset potentiometer. If zero speed cannot be obtained, refer to

a). It may be necessary to shield the velocity command lead. The

maximum common-mode range is ±10 V.

26

MSK7. Connection diagrams

7.1. Connection diagram - MTB-25

Fig. 11

27

MSK7.2. Connection diagram - MTB-25/MSK 6/MSK 12 with option \"24V

external\"

Fig. 12

28

MSK7.3. Connection diagram MSK 6/MSK 12 with motors M254-M506 and F504-F804

Fig. 13

M 254B-0M 254B-BM 256B-0M 256B-BM 404B-0M 404B-BM 404C-0M 404C-BM 404D-0M 404D-BM 406C-0M 406C-BM 406D-0M 404D-BM 504E-0M 504E-BM 504F-0M 504F-BM 506F-0M 506F-BF 504D-0F 504D-BF 634F-0F 634F-BF 804F-0F 804F-B0 = without brakeB = with brake29

MSKFront panel - MSK 6 / MSK 12 and MTB 25

Fig. 1430

7.4. MSK7.5. Dimensions

Fig. 15

31

MSK8. Ordering details

8.1. Order code for MSK, MTB and motherboards

MSK 12-ES1-AA

AB

=Standard version

Logic supply from bus voltage=Logic supply from external 24V

B-Z=Special version

ES1=With encoder simulation000=Without encoder simulation0612

=Current peak value 6 A=Current peak value 12 A

Module with sinusoidal commutation

MTB-25-85-012-AB

AB

=Without option

=With option (Ext. 24V + int. dump resistor)A=Standard

B-Z=Special version201

=No EMC test=Max. 5 axes

=Max. 6 or 7 axes

No significanceAC input

DC output currentPower supply module

Motherboard - type:MB-MSK

type:MB-MTB

32

MSK8.2. Order code for power dump resistors

Order codeHLMORU09 RK86 mm308 mm324 mm324 mm75 mm48 mm8.3. Order code for rack system

RSK 3-21-42

DU = width units

No. of power supply modulesNo. of servo modulesHU = height units

Rack module with sinusoidal commutation

33

MSK9. Appendix

9.1. Transformer dimensions and order code

Single-phase transformer to VDE 0550

Order codeTO 65.1TO 66.1Power0,5 kVA1,0 kVAa120150b130165c106142d90122e102127Three-phase transformers to VDE 0550

Order codeTO 118.1TO 119Power1,0 kVA2,3 kVAD240265T121152H210230b190215t961279.2. Motor cables

Type: KAB-MO motor cable (without a brake), shielded, 4 × 1.5 mm2, ∅ 10.9 mmType: KAB-MO-B motor cable (with a brake), shielded, 7 × 1.5 mm2, ∅ 13.9 mm

9.3. Resolver cable

Type: KAB-RES resolver cable, double shielded, 4 × 2 × 0.25 mm2, ∅ 11.5 mm

34